JLG 4013PS Service Manual

An Oshkosh Corporation Company
Service Manual
Models 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS,
4017PS,
Agrovector
40.8, 40.9
Revised
June 15, 2011
EFFECTIV IT Y PAGE
September 11, 2007 - A - Original Issue Of Manual April 4, 2008 - B - Revised pages 2.7, 2-8, 3.12, 3.27, 5.11, 7.3, 7.7, 7.8, 8.2, 8.9, 9.10, 9.28 and pages 9.30 thru 9.70.
Added platform information. June 15, 2011 - C - Update all
Loctite® 242
TM
, to Loctite
Revised pages 1-3, 2-3 thru 2-9, 2-13, 8-6 thru 8-16, 9-11 thru 9-21 & 9-34 thru 9-45.
®
243
TM
. Added models 40.8 & 40.9. Revised page numbering.
31200206 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
a
EFFECTIV IT Y PAGE
b
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 31200206
SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Replacement Parts and Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
2.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Section 3
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1 Boom System Component Terminology - Two and Three Section Boom . . . . . . . . . . . 3.3
3.2 Boom System - Two and Three Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3 Boom Assembly Maintenance - Two and Three Section Boom. . . . . . . . . . . . . . . . . . . 3.4
3.4 Boom System Component Terminology - Four Section Boom. . . . . . . . . . . . . . . . . . . . 3.8
3.5 Boom System - Four Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.6 Boom Assembly Maintenance - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.7 Boom Extend and Retract Chains Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.8 Boom Section Separation Adjustment - Four Section Boom . . . . . . . . . . . . . . . . . . . . . 3.21
3.9 Hose Carrier Assembly - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3.10 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.11 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3
4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
i
Section Subject Page
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing A Disabled Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Section 7
Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4
8.5 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.7 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.8 Auxiliary Pump (Platform Equipped Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.9 Valves and Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
ii
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section Subject Page
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.3 Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7
9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.7 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
9.8 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.9 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.11 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.12 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.13 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.14 Switches, Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.15 Load Stability Indicator (LSI) ­8, 9, 12 & 13M Before S/N 1160005993 excluding 1160005949 & 1160005950 17M Before S/N 1160005937 including 1160005952, 1160005960, 1160005963,
1160005966 & 1160005978. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
9.16 Load Stability Indicator (LSI) ­8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950 17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963,
1160005966 & 1160005978. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38
9.17 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
iii
Section Subject Page
iv
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
1-1
Safety Practices

1.1 INTRODUCTION

This service manual provides general directions for accomplishing servic e and re pai r proc edu res. Fo ll owi ng the procedures in this manual will help assure safety and equipment reliability.
Read, understand and follow the information in this manual, and obey all locally appro ved safe ty p r actices, procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during opera tion, maintenance, or testing. When additi onal information is desired consult the local JLG distributor.
Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator seat looking in a forwar d direction.
Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.

1.2 DISCLAIMER

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1.5 SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.
In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.5.1 Safety Alert System and Signal Words

DANGER
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
All information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3 OPERATION & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read and understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.
An Operation & Safety Manual is supplied with each machine and must be kept in the cab. In the event that the Operation & Safety Manual is missing, consult the local
JLG distributor before proceeding.
1-2
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructi ons to prov ide safety information before the potential of a hazard occurs.
For all safety messages, carefully read, understand and follow the instructions before

1.6.1 Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.
LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2 Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.
NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.
DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tool s onl y as re co mme nde d.
proceeding.

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.
HOUSEKEEPING: Keep the work area and operator cab clean, and remove all hazards (debris, oil, tools, etc.).
FIRST AID: Im mediately clean, dress and report a ll injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.
CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.
When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.
It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure the machine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, it is recommended a maximum pressure of 52 bar (750 psi) at a minimum distance of 30,5 cm (12 in) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation,
Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.
VENTILATION: Avoid prolonged engine operation in enclosed areas without ade quat e ventila tion.
SOFT SURFACES AND SLO P ES : NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the whe els blocked before performing any service.
FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.
FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
1-3
Safety Practices
pressure can explode. Hydraulic oil and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.
Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.
NEVER drain or store fluids in an open container. Engine fuel and hydraulic oil are flammable and can cause a fire and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explos ion.
PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.
LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.
TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.
NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.
MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.
BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7 SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.
1-4
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 2
General Information and Specifications
Contents
PARAGRAPH TITLE PAGE
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2-11
2.3.3 Platform Hydraulic Performance Specifications . . . . . . . . . . . . . . . . . . . . 2-11
2.3.4 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.5 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.6 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.1 8 Hour Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.2 50 Hour Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-1
General Information and Specifications
MZ1780
1

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

For reference when ordering replacement parts or making service inquiries about the machine, the machine serial number is required to help assure the provision of correct parts and information. Before ordering parts or initiating service inquiries, make note of the serial number located on the serial number plate (1).
Note: The replacement of any part on this machine with any other than a JLG authorized replacement part can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.
A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.
Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.
2-2
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2.2 TORQUE CHARTS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
Description
0100011
242
TM
Vibra-TITETM121
Medium Strength (Blue)
0100019
271
TM
Vibra-TITETM140
High Strength (Red)
0100071
262
TM
Vibra-TITETM131
Medium - High Strength (Red)
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
Values for ZincYellow Chromate Fasteners
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
(Dry)
Torque
Lubricated
3. *ASSEMBLYUSES HARDENED WASHER
NOTES: 1. THESE TORQUE VALUES DONOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUEVALUESARE STATICTORQUE MEASUREDPER STANDARD AUDIT METHODS TOLERANCE= ±10%
MY4510J
JLG P/N Loctite® P/N
ND Industries P/N
Torque
Loctite® 262™
OR
Vibra-TITE™ 131
Torque
Loctite® 242™ or 271™
OR
Vibra-TITE™ 111 or 140

2.2.1 SAE Fastener Torque Chart

General Information and Specifications
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-3
General Information and Specifications
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
In Sq In
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318
28 0.2500 0.0364
In Sq In
5/16 18 0.3125 0.0524
24 0.3125 0.0580
3/8 16 0.3750 0.0775
24 0.3750 0.0878
7/16 14 0.4375 0.1063
20 0.4375 0.1187
1/2 13 0.5000 0.1419
20 0.5000 0.1599
9/16 12 0.5625 0.1820
18 0.5625 0.2030
5/8 11 0.6250 0.2260
18 0.6250 0.2560
3/4 10 0.7500 0.3340
16 0.7500 0.3730
7/8 9 0.8750 0.4620
14 0.8750 0.5090
1 8 1.0000 0.6060
12 1.0000 0.6630
1 1/8 7 1.1250 0.7630
12 1.1250 0.8560
1 1/4 7 1.2500 0.9690
12 1.2500 1.0730
1 3/8 6 1.3750 1.1550
12 1.3750 1.3150
1 1/2 6 1.5000 1.4050
12 1.5000 1.5800
Values for Zinc Yellow Chromate Fasteners
3. *ASSEMBLY USES HARDENED WASHER
NOTES: 1. THESE TORQUEVALUES DO NOTAPPLYTO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17
LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000 45 60 40 55 35 50 7900 50 70 45 60 35 50
9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120 16400 155 210 140 190 115 155 18250 170 230 155 210 130 175 20350 210 285 190 260 160 220 23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475
87200 1815 2470 1635 2225 1365 1855
96600 2015 2740 1810 2460 1510 2055
104000 2385 3245 2145 2915 1785 2430
118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625
K=.18
K=0.15
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque
(Dry orLoctite® 263)
K= 0.20
MY4660J
Torque
Loctite® 262™
OR
Vibra-TITE™ 131
Torque
Loctite® 242™ or 271™
OR
Vibra-TITE™ 111 or 140
2.2.1 SAE Fastener Torque Chart (Continued)
2-4
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
See Note4
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS.IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.
SOCKET HEAD CAP SCREWS
Magni Coating*
Torque
(Dry) K = .17
K=0.16
K=0.15
2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM
MY4670J
Torque
Loctite® 262™
OR
Vibra-TITE™ 131
Torque
Loctite® 242™ or 271™
OR
Vibra-TITE™ 111 or 140
OR Precoat 85®
2.2.1 SAE Fastener Torque Chart (Continued)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-5
General Information and Specifications
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
See Note4
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS.IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.
SOCKET HEAD CAP SCREWS
Torque
(Dry)
K=.20
Torque
(Loctite® 242TMor 271
TM
OR Vibra-TITETM111 or
140 ORPrecoat 85®
K=0.18
Zinc Yellow Chromate Fasteners*
2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
K=0.15
MY4680J
2.2.1 SAE Fastener Torque Chart (Continued)
2-6
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2.2.2 Metric Fastener Torque Chart

Size PITCH
Tensile
Stress
Area
Clamp
Load
Torque
(Dry orLoctite®
263
TM
)
Torque
(Lub)
Sq mm KN [N.m] [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154
16 2 157 68.3
219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290
4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAWALUMINUM
Values for Zinc Yellow Chromate Fasteners
CLASS 8.8 METRIC BOLTS
CLASS 8 METRIC NUTS
NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS
2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
MY4690J
Torque
Loctite® 262™
OR
Vibra-TITE™ 131
Torque
Loctite®
242™ or 271™
OR
Vibra-TITE™
111 or 140
General Information and Specifications
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-7
General Information and Specifications
Size PITCH
Tensile
Stress
Area
Clamp
Load
K =0.20
K= 0.18
K=0.15
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150
16 2 157 97.8
315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395
Values for Zinc Yellow Chromate Fasteners
CLASS 10.9 METRIC BOLTS
CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAWALUMINUM
NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS
2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
MY4700J
Torque
Loctite® 262™
OR
Vibra-TITE™ 131
Torque Dry
or
Loctite® 263™
Torque
Lube OR Loctite®
242™ or 271™
OR
Vibra-TITE™
111 or 140
2.2.2 Metric Fastener Torque Chart (Continued)
2-8
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2.2.2 Metric Fastener Torque Chart
Size PITCH
Tensile
Stress
Area
Clamp Load
See Note4
K=.17
K=.16
K=.15
Sq mm kN [N.m] [N.m] [N.m]
3 0.5 5.03
3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150
16 2 157
97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395
CLASS 12.9 SOCKET HEAD CAP SCREWS
M6 ANDABOVE*
4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAWALUMINUM
NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS
2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
Magni Coating*
MY4710J
Torque
Loctite® 262™
OR
Vibra-TITE™ 131
Torque
Lube OR Loctite®
242™ or 271™
OR
Vibra-TITE™
111 or 140
Torque Dry
or
Loctite® 263™
(Continued)
General Information and Specifications
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-9
General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart
Size ORFS JIC Flats Method
4
6
8
10
12
16
20
24
13 lb-ft
(18 Nm)
23 lb-ft
(31 Nm)
40 lb-ft
(54 Nm)
60 lb-ft
(81 Nm)
74 lb-ft
(100 Nm)
115 lb-ft
(156 Nm)
170 lb-ft
(230 Nm)
200 lb-ft
(271 Nm)
13 lb-ft
(18 Nm)
23 lb-ft
(31 Nm)
40 lb-ft
(54 Nm)
60 lb-ft
(81 Nm)
85 lb-ft
(115 Nm)
115 lb-ft
(156 Nm)
170 lb-ft
(230 Nm)
200 lb-ft
(271 Nm)
1.5 to 1.75
1 to 1.5
1.5 to 1.75
1.5 to 1.75
1.0 to 1.5
0.75 to 1.0
0.75 to 1.0
0.75 to 1.0
Flats Method:
1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).
2. Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it’s connecting to.
3. Use the double wrench method while tightening to avoid hose twist.
4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots indicating that the con necti on has been properly tightened.
32 N/A
270 lb-ft
(366 Nm)
0.75 to 1.0
Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is not possible.
Torque Wrench:
1. Identify the appropriate application and refer to the above chart for the correct torque value.
2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).
3. Use the double wrench method while tightening to avoid hose twist.
4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks.
5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened.
2-10
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

Function Speed
First Gear 5 km/h (3.1 mph) Second Gear 10 km/h (6.2 mph) Third Gear 25 km/h (15.5 mph) Fourth Gear (Turbo Only) 35 km/h (21.7 mph)

2.3.2 Hydraulic Cylinder Performance Specifications

Note: Machine with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature.
Function
7M 8M 9M 12M 13M 17M
Boom Extend 11,60 11,60 13,30 14,03 16,88 23,0 Boom Retract 83 9,83 11,27 12,48 15,02 18,0 Boom Lift 8,28 9,43 14,0 12,32 14,00 15,5 Boom Lower 5,63 6,41 9,65 8,49 9,65 10,0 Attachment Tilt - UP 9,78 9,78 9,78 9,78 9,78 4,5 Attachment Tilt - DOWN 4,50 4,50 4,50 4,50 4,50 9,8 Outrigger - UP N/A N/A N/A 2,93 2,93 8,7 Outrigger - DOWN N/A N/A N/A 2,19 2,19 6,4 Frame Level 11,0 11,0 11,0 11,0 11,0 N/A
Approximate Times (sec.)

2.3.3 Platform Hydraulic Performance Specifications

Function
Platform Lift 31 39 Platform Lower 31 39
Approximate Times (sec.)
13M 17M
Platform Extend 19 27 Platform Retract 19 27 Platform Rotate 180° 14 14
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-11
General Information and Specifications

2.3.4 Electrical System

Note: Refer to Section 9.6, “Fuses and Relays,” for more information.
Battery
Type, Rating 12V DC, Negative (-) Ground, Limited Maintenance,
Wet Charged
Quantity 1 (100 Ah) (C
20
) Reserve Capacity CCA @ -18° C: 880 EN Group/Series DIN 600,38 Alternator 12V, 85 Amps Starter 12V, 3,2 KW Type EV (Gear Reduction)

2.3.5 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.
Description
Engine Make/Model Perkins 1004-40T Low Idle 925 RPM ±50 RPM High Idle 2340 RPM ±50 RPM Horsepower 80,4 BHP/60 KW @ 2200 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.3.6 Tires

Note: Standard wheel lug nut torque is 500 Nm (369 lb-ft).
Size Tire Type Minimum Ply Fill Type Pressure
405/70-24 MPT01 AG 14 Ply Pneumatic 4,0 Bar (58 psi) 405/70-24 MPT04 CONST 14 Ply Pneumatic 4,0 Bar (58 psi) 405/70-24 MPT01 AG (4017PS only) 14 Ply Pneumatic 4,5 Bar (65 psi) 405/70-24 MPT04 CONST (4017PS only) 14 Ply Pneumatic 4,5 Bar (65 psi)
2-12
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.4 FLUIDS, LUBRICANTS AND CAPACITIES

Engine Crankcase Oil
Capacity w/Filter Change 8,5 L (9 qt) Oil Type
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS
15W-40 CH
40.8 & 40.9 DF Super ENGINE OIL 15W-40
Fuel Tank
Capacity 140 L (37 gal) Type of Fuel #2 Diesel
Cooling System
System Capacity 20 L (5 gal) Type of Fluid 50/50 mix of ethylene glycol and water
Hydraulic System
System Capacity (8, 9M, 40.8 & 40.9) 220 L (58 gal) System Capacity (12, 13 & 17M) 240 L (63 gal) Reservoir Capacity to FULL Mark 160 L (42 gal)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS
Mobilfluid 424
®
(ISO 46)
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
Transmission
Capacity with Filter Change 12,9 L (13.6 qt)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS
Mobilfluid 424
®
(ISO 46)
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
Transfer Case
Capacity 1,4 L (1.5 qt)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS
Mobilfluid 424
®
(ISO 46)
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-13
General Information and Specifications
Axles
Differential Housing Capacity - Front 8,0 L (8.5 qt) Differential Housing Capacity - Rear 7,3 L (7.7 qt) Wheel End Capacity - Front 1,9 L (2.0 qt) Wheel End Capacity - Rear 1,4 L (1.5 qt)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS
Mobilfluid 424
®
(ISO 46)
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
Brake System
System Capacity 1,0 L (1.1 qt) Type of Oil
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS
Dexron II or III ATF
40.8 & 40.9 DONAX TA
Air Conditioning System (if equipped)
System Capacity 2,05 kg (4.5 lb) Type of Refrigerant R-134a Tetrafluoroethane Type of Lubricant PAG-oil SP-20, TXV System Quantity of Lubricant 68,3 ccm (2.3 oz)
2-14
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
MZ1671
Air Filter
Check Fuel
Level
Check Engine
Oil Level
Check
Transmission
Oil Level
Check Hydraulic
Oil Level
Check Tire
Condition &
Pressure
Check Brake
Fluid Level
8
EVERY
Additional Checks -
Operation &
Safety Manual
Check Wheel
Lug Nut
Torque
LB/FT (Nm)
Change Axle Oil
Change Wheel
End Oil
50
1
st
Check Boom
Chain & Tension
(17M Only)
Change Engine
Oil & Filter
Change
Transmission
Oil & Filter
MZ1681
250
EVERY
Check Axle
Oil Level
Check Wheel
End Oil Levels
Air Filter
Vacuator
Valve
Check
Fan Belt
Check Boom
Chain & Tension
(17M Only)
Check Boom
Wear Pads
Check Transfer
Case Oil Level
Change Engine
Oil and
Filter
Check LSI
Calibration
500
EVERY
Check Wheel
Lug Nut
Torque
LB/FT (Nm)
Change Fuel
Filter
50
EVERY
Drain Fuel/
Water
Separator
Check Engine Coolant Level
Lubrication
Schedule
Check
Battery
Check Washer
Fluid Level
MZ1690
1500
EVERY
Change
Engine Coolant
Change
Hydraulic
Fluid & Filters
Change
Hydraulic Tank
Breather
Change
Brake Fluid
1000
EVERY
Change Axle Oil
Change Wheel
End Oil
Change
Transmission
Oil & Filter
Change
Transfer Case
Oil

2.5 MAINTENANCE SCHEDULES

2.5.1 8 & 1st 50 Hour Maintenance Schedule

2.5.2 50, 250 & 500 Hour Maintenance Schedule

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2.5.3 1000 & 1500 Hour Maintenance Schedule

2-15
General Information and Specifications
EVERY
8
OZ2260

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lubrication Schedule

8, 9, 12 & 13M
2-16
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
17M
OZ2430
EVERY
8
General Information and Specifications
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-17
General Information and Specifications
2x
OZ2270
50
EVERY

2.6.2 50 Hour Lubrication Schedule

8, 9, 12 & 13M
2-18
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
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